ION 2006-2007

Precautions

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Before servicing the air conditioning system on any vehicle, please be sure to read all of the following precautions, which deal with personal safety, prevention of component damage, and important points to take into consideration when servicing the air conditioning system:



Eye protection MUST be worn when servicing an A/C refrigerant system. Turn all valves off (rotate clockwise) on the equipment being used before connecting or disconnecting service equipment from the refrigerant system. Failure to observe these warnings may result in personal injury or death.
 
Never add R-12 to a refrigerant system designed to use R-134a. Do not use R-12 equipment or parts on a R-134a A/C system. These refrigerants are not compatible and damage to the A/C system will result.
 
Never use R-12 refrigerant oil in a A/C system designed to use R-134a refrigerant oil. These refrigerant oils are not compatible and damage to the A/C system will result.
 
The use of A/C system sealers may result in damage to A/C refrigerant recovery/evacuation/recharging equipment and/or A/C system. Many federal, state/provincial and local regulations prohibit the recharge of A/C systems with known leaks. DaimlerChrysler recommends the detection of A/C system leaks through the use of approved leak detectors and fluorescent leak detection dyes. Vehicles found with A/C system sealers should be treated as contaminated and replacement of the entire A/C refrigerant system is recommended. A/C systems found to be contaminated with A/C system sealers, A/C stop-leak products or seal conditioners voids the warranty for the A/C system.
 
Recover the refrigerant before opening any fitting or connection. Open the fittings with caution, even after the system has been discharged. Never open or loosen a connection before recovering the refrigerant.
 
If equipped, do not remove the secondary retention clip from any spring-lock coupler connection while the refrigerant system is under pressure. Recover the refrigerant before removing the secondary retention clip. Open the fittings with caution, even after the system has been discharged. Never open or loosen a connection before recovering the refrigerant.
 
The internal parts of the A/C system will remain stable as long as moisture-free refrigerant and refrigerant oil is used. Abnormal amounts of dirt, moisture or air can upset the chemical stability. This may cause operational troubles or even serious damage if present in more than very small quantities. Before disconnecting a component, clean the outside of the fittings thoroughly to prevent contamination from entering the refrigerant system. Keep service tools and the work area clean. Do not open the refrigerant system or uncap a replacement component until you are ready to service the system. Immediately after disconnecting a component from the refrigerant system, seal the open fittings with a cap or plug. This will prevent contamination from entering the A/C system.
 
Refrigerant oil will absorb moisture from the atmosphere if left uncapped. Do not open a container of refrigerant oil until you are ready to use it. Replace the cap on the oil container immediately after using. Store refrigerant oil only in a clean, airtight, and moisture-free container.
 
Do not overcharge the refrigerant system. Overcharging will cause excessive compressor head pressure and can cause compressor noise and A/C system failure.
 

Charging The System




CAUTION
Refer to the applicable precautions for this system before performing the following operation. Failure to follow the warnings and cautions could result in possible personal injury or death.


NOTE
Always refer to the under right hand hood HVAC Specification Label for the refrigerant fill specification of the vehicle being serviced.

After all refrigerant system leaks have been repaired and the refrigerant system has been evacuated, a refrigerant charge can be injected into the system. For the proper amount of the refrigerant charge, refer to the under right hand hood HVAC Specification Label.


NOTE
A R-134a refrigerant recovery/recycling/charging station that meets SAE Standard J2210 must be used to charge the refrigerant system with R-134a refrigerant. Refer to the operating instructions supplied by the equipment manufacturer for proper care and use of this equipment.


WARNING
A small amount of refrigerant oil is removed from the A/C system each time the refrigerant system is recovered and evacuated. Before charging the A/C system, you MUST replenish any oil lost during the recovery process. Refer the equipment manufacturer instructions for more information.

  1. Evacuate the refrigerant system as outlined in this section.
  2.  
  3. A manifold gauge set and an R-134a refrigerant recovery/recycling/charging station that meets SAE standard J2210 should be connected to the refrigerant system.
  4.  
  5. Measure the proper amount of refrigerant and heat it to 125° F (52° C) with the charging station. See the operating instructions supplied by the equipment manufacturer for proper use of this equipment.
  6.  
  7. Open both the suction and discharge valves, then open the charge valve to allow the heated refrigerant to flow into the system.
  8.  
  9. When the transfer of refrigerant has stopped, close both the suction and discharge valves.
  10.  
  11. If all of the refrigerant charge did not transfer from the dispensing device, open all of the windows in the vehicle and set the heating-A/C system controls so that the A/C compressor is engaged and the blower motor is operating at its lowest speed setting. Run the engine at a steady high idle (about 1400 rpm). If the A/C compressor does not engage, test the compressor clutch control circuit and repair as required. Open the low-side valve to allow the remaining refrigerant to transfer to the refrigerant system.
    CAUTION
    Take care NOT to open the discharge (high pressure) valve at this time. Failure to follow this warning could result in possible personal injury or death.

  12.  
  13. Disconnect the charging station and manifold gauge set from the refrigerant system service ports.
  14.  
  15. Reinstall the caps onto the refrigerant system service ports.
  16.  

Evacuating The System




CAUTION
Refer to the applicable precautions for this system before performing the following operation. Failure to follow the warnings and cautions could result in possible personal injury or death.


NOTE
Special effort must be used to prevent moisture from entering the A/C system oil. Moisture in the oil is very difficult to remove and will cause a reliability problem with the compressor. If an A/C compressor designed to use R-134a refrigerant is left open to the atmosphere for an extended period of time. It is recommended that the refrigerant oil be drained and replaced with new oil or a new A/C compressor be used. This will eliminate the possibility of contaminating the refrigerant system.


NOTE
If the refrigerant system has been open to the atmosphere, it must be evacuated before the system can be filled. Moisture and air mixed with the refrigerant will raise the compressor head pressure above acceptable operating levels. This will reduce the performance of the A/C system and damage the A/C compressor. Moisture will boil at near room temperature when exposed to vacuum. To evacuate the refrigerant system:


NOTE
When connecting the service equipment coupling to the line fitting, verify that the valve of the coupling is fully closed. This will reduce the amount of effort required to make the connection.

  1. Recover the refrigerant system, as outlined in this section.
  2.  
  3. Connect a suitable charging station, refrigerant recovery machine or a manifold gauge set with vacuum pump and refrigerant recovery equipment. Refer to System Service Equipment in this section.
  4.  
  5. Open the suction and discharge valves and start the vacuum pump. The vacuum pump should run a minimum of 45 minutes prior to charge to eliminate all moisture in system. When the suction gauge reads - 26 in. Hg (88 kPa) vacuum or greater for 30 minutes, close all valves and turn off vacuum pump. If the system fails to reach specified vacuum, the refrigerant system likely has a leak that must be corrected. If the refrigerant system maintains specified vacuum for at least 30 minutes, start the vacuum pump, open the suction and discharge valves. Then allow the system to evacuate an additional 10 minutes.
  6.  
  7. Close all valves. Turn off and disconnect the vacuum pump.
  8.  
  9. Charge the refrigerant system as outlined in this section.
  10.  

System Recovery




CAUTION
Refer to the applicable precautions for this system before performing the following operation. Failure to follow the warnings and cautions could result in possible personal injury or death.

An R-134a refrigerant recovery/recycling/charging station (1) that meets SAE standard J2210 must be used to recover the refrigerant from the R-134a refrigerant system. Refer to the operating instructions supplied by the equipment manufacturer for the proper care and use of this equipment.

Click image to see an enlarged view

Fig. An R-134a refrigerant recovery/recycling/charging station (1) that meets SAE standard J2210 must be used to recover the refrigerant from the R-134a refrigerant system. Refer to the operating instructions supplied by the equipment manufacturer for the proper care and use of this equipment

System Service Equipment




CAUTION
Eye protection MUST be worn when servicing an A/C refrigerant system. Turn all valves off (rotate clockwise) on the equipment being used before connecting or disconnecting service equipment from the refrigerant system. Failure to observe these warnings may result in personal injury or death.


CAUTION
Refer to the applicable precautions for this system before performing the following operation. Failure to follow the warnings and cautions could result in possible personal injury or death.

When servicing the A/C system, a R-134a refrigerant recovery/recycling/charging station that meets SAE standard J2210 must be used. Contact an automotive service equipment supplier for refrigerant recovery/recycling/charging equipment. Refer to the operating instructions supplied by the equipment manufacturer for proper care and use of this equipment.

A manifold gauge set may be needed with some recovery/recycling/charging equipment. The manifold gauge set should have manual shut-off valves (2 and 6), or automatic back-flow valves located at the service port connector end of the manifold gauge set hoses (4 and 5). This will prevent refrigerant from being released into the atmosphere.

Click image to see an enlarged view

Fig. An R-134a refrigerant recovery/recycling/charging station (1) that meets SAE standard J2210 must be used to recover the refrigerant from the R-134a refrigerant system. Refer to the operating instructions supplied by the equipment manufacturer for the proper care and use of this equipment



Click image to see an enlarged view

Fig. A manifold gauge set (1) may be needed with some recovery/recycling/charging equipment. The manifold gauge set should have manual shut-off valves (2 and 6), or automatic back-flow valves located at the service port connector end of the manifold gauge set hoses (4 and 5). This will prevent refrigerant from being released into the atmosphere.

Manifold Gauge Set Connections

WARNING
Do not use an R-12 manifold gauge set on an R-134a system. The refrigerants are not compatible and system damage will result.

RECOVERY/RECYCLING/EVACUATION/CHARGING HOSE- The center manifold hose (Yellow, or White, with Black stripe) (3) is used to recover, evacuate, and charge the refrigerant system. When the low or high pressure valves on the manifold gauge set are opened, the refrigerant in the system will escape through this hose.

HIGH PRESSURE GAUGE HOSE - The high pressure hose (Red with Black stripe) (4) attaches to the high side service port. This service port is located on the A/C liquid line next to the left shock tower. On this model, an A/C pressure transducer is also installed on the liquid line. A/C high-side pressures can be read using a scan tool. Refer to 9 - Engine Electrical Diagnostics for more information.

LOW PRESSURE GAUGE HOSE - The low pressure hose (Blue with Black stripe) (5) attaches to the low side service port. This service port is located on the A/C suction line behind the left shock tower.

Click image to see an enlarged view

Fig. A manifold gauge set (1) may be needed with some recovery/recycling/charging equipment. The manifold gauge set should have manual shut-off valves (2 and 6), or automatic back-flow valves located at the service port connector end of the manifold gauge set hoses (4 and 5). This will prevent refrigerant from being released into the atmosphere.

 
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